Harness adjustment mechanism for a child vehicle seat

ABSTRACT

A child vehicle seat includes a seat assembly including an upright portion having a first passage and a second passage defined therein. The child vehicle seat further includes a harness system including (i) a first shoulder belt portion extending through the first belt passage, and (ii) a second shoulder belt portion extending through the second belt passage. Also, the child vehicle seat includes a retractor assembly configured to receive belt portions of the harness system in a wound configuration, the retractor assembly including a spring which urges belt portions of the harness system into the retractor assembly. Moreover, the child vehicle seat includes an actuator positionable between (i) a first position in which the actuator prevents payout of belt portions from the retractor assembly, and (ii) a second position in which the actuator allows payout of belt portions from the retractor assembly. The retractor assembly further includes a manual adjustment mechanism, and manual movement of the manual adjustment mechanism causes further belt portions of the harness system to be advanced into the retractor assembly.

This application claims the benefit of both (i) U.S. ProvisionalApplication Ser. No. 60/619,182, filed Oct. 15, 2004, and (ii) U.S.Provisional Application Ser. No. 60/718,458, filed Sep. 19, 2005. Thedisclosure of both of the above-identified provisional patentapplications are hereby totally incorporated by reference in theirentirety.

BACKGROUND

This invention relates to the field of child seats for motor vehicles.

Child seats for motor vehicles are widely used by operators of motorvehicles to protect children from harm in the event of an accident.Child seats generally include a plastic shell with a cushioned seatformed over the shell. A harness is provided on the seat to restrain thechild and retain the child in the seat in the event of an accident.Harness systems typically include a shoulder harness with belts designedto extend over the shoulders of the child and a buckle harness with acrotch belt designed to extend between the legs of the child. The beltsincluded with the harness system can typically be adjusted in length toaccommodate children of different sizes.

However, the ability to further adjust the harness system to take up anyslack present after a child has been buckled in the seat with this typeof length adjusting system has been lacking. In particular, such systemsdo not automatically take up slack after the child has been buckled inthe seat. Therefore, a need exists for a child seat which allows forautomatic removal of slack after the child has been buckled in the seat.Moreover, it would be advantageous if such child seat allowed furthermanual slack removal after a majority of the slack has beenautomatically removed by the seat system. In addition, it would bedesirable if such child seat was easy to use and inexpensive tomanufacture.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the present invention, there isprovided a child vehicle seat that includes a seat assembly including(i) a seat portion having a first belt passage defined therein, and (ii)an upright portion having a second passage defined therein. The childvehicle seat further includes a harness system including (i) a shoulderbelt portion extending through the first belt passage, and (ii) a crotchbelt portion extending through the second belt passage. Moreover, thechild vehicle seat includes a retractor assembly configured to receivebelt portions of the harness system in a wound configuration, theretractor assembly including a spring which urges belt portions of theharness system into the retractor assembly. In addition, the childvehicle seat includes an actuator positionable between (i) a firstposition in which the actuator prevents payout of belt portions from theretractor assembly, and (ii) a second position in which the actuatorallows payout of belt portions from the retractor assembly. Theretractor assembly further includes a manual adjustment mechanism, andmanual movement of the manual adjustment mechanism causes further beltportions of the harness system to be advanced into the retractorassembly.

In accordance with another embodiment of the present invention, there isprovided a child vehicle seat that includes a seat assembly including anupright portion having a passage defined therein. The child vehicle seatalso includes a harness system including a shoulder belt portionextending through the passage. Moreover, the child vehicle seat includesa retractor assembly configured to receive belt portions of the harnesssystem in a wound configuration, the retractor assembly including aspring which urges belt portions of the harness system into theretractor assembly. The child vehicle seat further includes an actuatorpositionable between (i) a first position in which the actuator preventspayout of belt portions from the retractor assembly, and (ii) a secondposition in which the actuator allows payout of belt portions from theretractor assembly. The retractor assembly further includes a manualadjustment mechanism, and manual movement of the manual adjustmentmechanism causes further belt portions of the harness system to beadvanced into the retractor assembly.

In accordance with yet another embodiment of the present invention,there is provided a child vehicle seat that includes a seat assemblyincluding an upright portion having a first passage and a second passagedefined therein. The child vehicle seat further includes a harnesssystem including (i) a first shoulder belt portion extending through thefirst belt passage, and (ii) a second shoulder belt portion extendingthrough the second belt passage. Also, the child vehicle seat includes aretractor assembly configured to receive belt portions of the harnesssystem in a wound configuration, the retractor assembly including aspring which urges belt portions of the harness system into theretractor assembly. Moreover, the child vehicle seat includes anactuator positionable between (i) a first position in which the actuatorprevents payout of belt portions from the retractor assembly, and (ii) asecond position in which the actuator allows payout of belt portionsfrom the retractor assembly. The retractor assembly further includes amanual adjustment mechanism, and manual movement of the manualadjustment mechanism causes further belt portions of the harness systemto be advanced into the retractor assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a partial cutaway perspective side view of a child vehicleseat and restraint system;

FIG. 2 shows a perspective view of a frame of the child vehicle seat ofFIG. 1;

FIG. 3 shows a front perspective view of the child vehicle seat of FIG.1 with the seat cover and foam shell removed;

FIG. 4 shows a rear perspective view of the child vehicle seat of FIG. 1with the headrest and seat cover removed;

FIG. 5 shows a rear view of the child vehicle seat of FIG. 1;

FIG. 6 shows a front perspective view of the foam shell of the childvehicle seat of FIG. 1;

FIG. 7 shows a front perspective view of the child vehicle seat of FIG.1 with a seat cover and headrest foam removed and the headrest in a downposition;

FIG. 8 shows a front perspective view of the child vehicle seat of FIG.7 with the headrest in an up position;

FIG. 9 shows a front perspective view of the headrest support of thechild vehicle seat of FIG. 1 with the headrest removed from the headrestsupport;

FIG. 10 shows a fully assembled front perspective view of the childvehicle seat of FIG. 1;

FIG. 11 shows a rear perspective view of the child vehicle seat of FIG.10;

FIG. 12 shows the harness arrangement in relation to the frame for thechild vehicle seat of FIG. 1;

FIG. 13 shows a front perspective view of the harness of the childvehicle seat of FIG. 12 with the harness unbuckled;

FIG. 14 shows a top perspective view of the child vehicle seat of FIG.13 with a crotch strap in an extended position;

FIG. 14A shows a top perspective view of an alternative embodiment tothe arrangement shown in FIG. 14 in which a tether belt is utilized tolimit upward movement of the front buckle, and showing the crotch strapin an extended position;

FIG. 15 shows a top perspective view of the child vehicle seat of FIG.13 with a crotch strap in a retracted position;

FIG. 15A shows a top perspective view of the alternative embodiment ofFIG. 14A in which the crotch strap is shown in a retracted position;

FIG. 16 shows a front view of the headrest support of the child vehicleseat of FIG. 1, and showing the adjustment bar;

FIG. 16A shows a front view of an alternative embodiment of a headrestsupport of the child vehicle seat, and showing an alternative embodimentof the adjustment bar in relation to that shown in FIG. 16;

FIG. 17 shows a partial cutaway top perspective view of the child seatof FIG. 1 exposing the retractor and latch mechanism;

FIG. 18 shows a front perspective view of the retractor mechanism ofFIG.

FIG. 19A shows a cross-sectional view of the belt retractor of FIG. 17;

FIG. 19B shows a rear elevational view of the belt retractor of FIG.19A;

FIG. 19C is a cross-sectional view of the belt retractor taken along theline A-A of FIG. 19A;

FIG. 20 shows a bottom perspective partial cutaway view of the childvehicle seat of FIG. 1;

FIG. 21 shows a top front perspective view of an alternative embodimentof the child vehicle seat of FIG. 1 with a removable seat cover;

FIG. 21A shows an alternative embodiment of the headrest cover inrelation to the headrest cover shown in FIG. 21;

FIG. 22 shows another top front perspective view of the child vehicleseat of FIG. 21 with the seat cover partially removed;

FIG. 23 shows an alternative front perspective view of the shoulderbelts of the child vehicle seat of FIG. 13;

FIG. 24 shows a front perspective view of the shoulder belts andshoulder pads of FIG. 23;

FIG. 25 shows a rear perspective view of the child vehicle seat of FIG.1 including a carrying strap;

FIG. 25A shows a rear perspective view of an alternative embodiment ofthe child seat in relation to the embodiment shown in FIG. 25, with thealternative embodiment including an anti-skid material adhered orotherwise affixed to the bottom surface of the bottom portion of thebase shell of the child seat;

FIG. 26 shows a rear perspective view of the child vehicle seat of FIG.25 with the carrying strap hooked to the vehicle seat;

FIG. 27 shows a perspective view of the child vehicle seat of FIG. 25being carried by a user;

FIG. 28 shows a top view of the child vehicle seat of FIG. 21;

FIG. 29 shows a top perspective view of the child vehicle seat of FIG.28 with the instruction flap pulled back;

FIGS. 30A and 30B show perspective views of two separated locking piecesof a fastener for the child vehicle seat of FIG. 21;

FIG. 31 shows a perspective view of the locking pieces of FIG. 30 in anengaged position; and

FIG. 32 shows a page of an instruction manual for the child vehicle seatof FIG. 1.

DESCRIPTION

Overview

With general reference to FIG. 1, a child's vehicle seat and restraintsystem 100 comprises a seat portion 104 and a headrest 102. The seatportion 104 of the child seat 100 includes a base shell 118 which issecured to the posterior side of a rigid frame 122. A foam shell 120 issecured to the base shell 118 and covers the anterior side of the rigidframe. The headrest 102 is attached to an adjustable headrest support130 which is slideably retained upon the frame.

As shown in FIG. 12, the child seat 100 also includes a harness 110which is designed to secure an occupant within the seat. The harness 110includes a plurality of straps that form a web 200 used to secure achild in the seat. The harness 110 also includes a front buckle 112 anda front clip 114 used to properly position the harness straps upon thechild. A central belt retractor 300 is secured to the rigid frame 122and is operable to remove slack in the harness once a child occupant ispositioned in the child seat 100.

Frame

With reference to FIG. 2, the frame 122 of the child seat includes twoL-shaped members 126 separated by a plurality of metallic cross members128 that extend between the L-shaped members 126. The cross members 128extend through holes defined in the L-shaped members 126 and arefastened to the L-members using means commonly used in the art, such aswelding or nuts and bolts. Each L-shaped member includes a short leg132, a curved portion 134, and a long leg 136. Two parallel support bars138 are also included in the frame. Each support bar 138 includes afirst end connected to the short leg 132 of one of the L-shaped members126 and a second end that extends toward the top of the long leg 136 ofthe same L-shaped member 126. An S-shaped plate 140 connects the secondend of each support member to the long leg 136 of the L-shaped member126. One of the cross members 128 extends through the first end of thesupport bars 138 to secure the support bars to the short legs 132 of theL-shaped members 126. An additional metallic cross member 129 isprovided that extends between the support bars 138 and through theS-shaped plates. The rigid frame 122 is made of a lightweight metallicmaterial, such as aluminum.

The frame 122 generally provides a strong skeletal structure for thechild seat 100 to which all load bearing components on the child seatare attached. Because the frame 122 is comprised of a metal material,the frame provides a stable support that resists cracking and/orbreaking. With this arrangement, force is directed away from theoccupant of the child seat in the event of a crash.

Base Shell

With reference to FIGS. 1 and 3, the base shell 118 cradles the frame122 about the posterior side of the frame 122. To this end, the profileof the base shell 118 is generally L-shaped, similar the L-shapedmembers 126 of the frame 122. The base shell 118 is made of a relativelystiff plastic material, such as polypropylene. The base shell 118includes a bottom portion 150 designed to receive the short legs 132 ofthe frame 122, and a back portion 152 designed to receive the long legs136 of the frame 122. The frame 122 is secured to the base shell 118 inany means commonly used in the art such as rivets, nuts and bolts, orother fasteners.

As shown in FIGS. 4 and 5, the back portion 152 of the base shell 118includes a recessed angled panel 156 positioned between two rear heels158. A window 160 is formed in the back portion 152 above the recessedangled panel 156. The window 160 is flanked by two side wings 162. A toppanel 164 is formed above the window 160 and extends between the twoside wings 162. Two columns 166 extend from the top panel 164 down tothe heels 158. The two columns 166 partially surround the long legs 136of the L-shaped members 126 of the frame 122. Triangular openings 168are formed between the wings 162, columns 166 and heels 158, as shown inFIG. 4.

The bottom portion 150 of the base shell 118 includes a generally flatportion designed to provide a surface for the base shell that rests uponthe vehicle seat. The bottom portion 150 of the base shell is best seenin FIGS. 25 and 26. Anti-skid material may be adhered or otherwiseaffixed to the bottom surface of the bottom portion 150 of the baseshell to discourage the base shell from moving when it is placed in avehicle seat as shown in an alternative embodiment depicted in FIG. 25A.The anti-skid material is generally a resilient material such as rubberor soft plastic and is textured to provide additional gripping abilityon a vehicle seat.

The two rear heels 158 also blend into the bottom portion 150 of thebase shell and provide additional support for the base shell when it isplaced in the vehicle seat. The bottom portion 150 of the base shell 118is cupped by the two side wings 162 which extend down from the backportion 152 and into the bottom portion 150 of the base shell. The shortlegs 132 of the frame 122 are located in the cupped bottom portion. Asshown in FIG. 14, the bottom portion 150 of the base shell 118 alsoincludes a central channel 154 through which a harness belt passes.

Foam Shell

With reference now to FIG. 6-8, the top foam shell 120 is generally asingle integral component. The foam shell generally comprises a seat 170and a backrest 172. Two arm rests 174 flank the seat 170, and a recess176 is formed in the front of the seat, as shown in FIG. 6. The armrests flow into two sidewalls 178 that flank the backrest 172. Anopening is formed in the backrest for receiving the adjustable headrestsupport 130. The foam shell 120 is made of a dense foam material, suchas ethylene propylene copolymer, with a density ranging between 20 g/land 180 g/l. In one preferred embodiment, the dense foam material isethylene propylene copolymer with a density of 30 g/l. Such foammaterial is sold by JPS International under the trademark ARPRO®expanded polypropylene beads. The foam shell is relatively flexiblecompared to the more rigid portions of the child seat 100, and isdesigned to cradle the occupant of the child seat in the event of sideimpacts. The foam shell is soft to the touch and is configured to absorba significant amount of energy in the event of a crash. In addition,extreme temperatures have relatively little effect on the foam shell sothat cracking of the foam shell does not occur in the event of avehicular accident. The foam shell is designed and configured to cushionthe occupant and protect the occupant in the event of an accident.

As described above, the foam shell is positioned over the anterior sidesof the frame 122 and base shell 118. The frame 122 is thus generallyenclosed by a two-part shell which includes the base shell 118 on oneside and the foam shell 120 on the other side. The foam shell 120 issecured to the frame 122 and/or base shell 118 using any of variousfastening methods known to those of ordinary skill in the art. Forexample, the foam shell 120 may be secured to the base and frame usinghook and loop type fastener strips, such as those sold under thetrademark VELCRO®, or nuts and bolts or other fasteners.

An exemplary fastener 360 which may be used to secure the foam headrest102 to the headrest support 130 is shown in FIGS. 30A, 30B, and 31. Thefastener 360 includes two complementary molded locking pieces 362 and364. Each locking piece includes a circular anchor 366 with an extendingpost 368. The extending post includes two opposing tines 370 and 372.Each tine 370, 372 includes a first plurality of teeth 374 axiallypositioned along one interior side and a second plurality of teeth 376axially positioned along another interior side such that the firstplurality of teeth 374 are 90° offset from the second plurality of teeth376. When the posts 368 are mated, the tines 370, 372 from one lockingpiece 362 slide along the tines 370, 372 of the opposite locking piece364, and the teeth 374, 376 on the tines act in a ratcheting fashion,such that the posts 368 can only become further engaged, and are lockedfrom disengagement. When the posts 368 are fully engaged, the lockingpieces 362, 364 are fastened and cannot be pulled apart withoutdestruction of the locking pieces. When used on the seat 100, thecircular anchor 366 from one locking piece 362 is embedded in the foamshell with its post 368 extending through a hole 363 defined in the foamheadrest 102 (see, e.g., FIG. 1). The post 368 of the other lockingpiece 364 extends through a hole 365 defined in the headrest support 130(see, e.g., FIGS. 7 and 8). When the two posts 368 are engaged, theratcheting action on the teeth locks the posts together, therebysecuring the foam headrest 102 to the headrest support 130.

Headrest Support

With reference to FIGS. 1 and 7-9, the headrest support 130 is generallyrectangular in shape and is adjustably mounted on the parallel supportbars 138 of the frame 122. The headrest support 130 includes a frontface 182 and a rear face 184. As best seen in FIG. 9, u-shaped channels190 are positioned along the edges of the headrest support. The u-shapedchannels 190 are designed to curve around and receive the support bars138, thus guiding the headrest support 130 as it slides up and downalong the support bars 138. The headrest support 130 includes a forwardportion 131 (see, e.g., FIGS. 7 and 8) and a rear portion 133 (see,e.g., FIG. 9). The forward portion 131 and the rear portion are securedtogether, and thus, move in unison during adjustment of the headrestsupport 130.

As discussed above, the headrest is mounted directly on the headrestsupport 130. For example, fasteners 360, such as those shown in FIGS.30A, 30B, and 31 may be used to secure the headrest 102 to the headrestsupport 130. In an alternative embodiment, a resilient foam material isinterposed between the forward portion 131 of the headrest 130 and therear portion 133 of the headrest 130. The resilient foam materialprovides cushioned support for the headrest.

The front face 182 of the headrest support 130 also includes two beltguides 186. The two belt guides 186 extend from the front face 182 andprovide for passage of the harness straps 200 through the headrestsupport. The headrest 102 includes holes designed to allow the beltguides 186 to extend through the foam cushion of the headrest. Asexplained in further detail below, the belt guides 186 also properlyposition the harness straps at various vertical heights as the headrestsupport 130 and headrest 102 are moved to account for children ofdifferent sizes in the child seat 100. A slit 198 is also defined in theheadrest support 130 to provide an additional passage from the frontface 182 to the rear face 184. As explained in further detail below, theslit 198 is designed to receive the end of one of the harness belts, andsecure it to the headrest support 130, thereby assisting inautomatically adjusting the harness as the headrest support 130 andheadrest 102 are moved.

Also included on the front face 182 of the headrest support 130, behindthe headrest 102, is a panel adjustment mechanism 148. With reference toFIGS. 9 and 16, the panel adjustment mechanism includes a horizontalcenter track 191 defined in the headrest support 130. Two pins 193 arepositioned in the horizontal center track 191. The two pins 193 arebiased toward the outer edges of the track 191 by a center spring 192.Each pin 193 includes a locking post (not shown) designed to extend outof an end the track 191 and into one of a plurality of holes 149 in thesupport bar 138 of the frame. However, each of the two pins 193 areslideable within the track 191 such that the locking posts may beremoved from the holes 149 in the support bar if the pins 193 are moveda sufficient distance toward the center of the track 191 against thebias of center spring 192. A knob 194 is provided on each pin 193 tofacilitate movement of the pin within the track 191. As best seen inFIG. 16, each knob 194 extends out of the track and contacts an angledcam surface 146 on the end of an adjustment bar 144 that is slideablymounted to the front face 182 of the headrest support 130. The angledcam surface 146 is defined by two angled slots 187 (see, e.g., FIG. 16A)such that opposing sides of the surface are further apart near thebottom than at the top. The opposite end of the adjustment bar 144includes a handle 142 (see FIGS. 7-8). The handle 142 is spring biasedin a downward position.

According to the above arrangement, when a user pulls up the handle 142,the adjustment bar 144 slides upward and the angled surface 146 of anangled slot also moves upward. As the angled cam surface 146 slidesupward, the knobs 194 on the pins 193 ride along the angled cam surface,forcing the pins 193 closer together, toward the center of the track.When the pins 193 are moved to the center of the track, the lockingposts on the pins are removed from the holes 149 in the support bar 138.Accordingly, the headrest support 130 and connected headrest 102 arefree to slide along the support bar 138. When the proper position forthe headrest 102 is found, the user releases the handle 142 and thehandle returns to a downward position. As the handle 142 returns to thedownward position, the adjustment bar 144 and angled cam surface 146also move downward, allowing the knobs 194 on the pins 193 in the track191 to move further apart. The spring 192 then forces the pins apart,thereby forcing the locking posts into the holes 149 in the support bar138 when the locking posts are properly aligned with the holes 149. FIG.16 shows an alternative embodiment of an adjustment bar 144′ possessingan alternative camming arrangement configured generally to possess aninverted U-shape or inverted V-shape. With such an alternativearrangement, the operator would push down on the handle 142 in order toremove the pins 193 from the corresponding holes 149 defined in thesupport bar 138 so that the headrest support 130 could be adjusted.

Headrest

With reference to FIGS. 1, 10 and 11, the headrest 102 is mounted on thetop portion of the headrest support 130. The headrest 102 is comprisedof the same material as the foam shell 120. In particular, the headrestis comprised of a dense foam material, such as ethylene propylenecopolymer. Such foam material is commercially available through JPSInternational under the trademark ARPRO® expanded polypropylene beads.

The headrest 102 includes a central portion 101 that is secured to theheadrest support 130. The central portion 101 includes two shoulderharness slots 105 that are aligned with the harness guides 186, allowingstraps to pass through the headrest support 130 and headrest 102. Thecentral portion 101 of the headrest 102 is integral with two flexiblesidewalls 103 having generally curved perimeters. Each sidewall 103extends about 6 to 12 inches outward and away from the location wherethe central portion 101 is attached to the headrest support 130. Eachsidewall 103 also curves around the base shell 118 as it extends awayfrom the central portion 101. While the central portion 101 is securelyfastened to the headrest support 130, the sidewalls 103 are free to bendin relation to the central portion 101. In particular, the sidewalls 103of the headrest 102 are free to pivot near the point where the headrest102 is fastened to the headrest support 130 and toward an occupant'shead sitting in the child seat 100 in the event of an accident. Thisprovides a significant amount of protection for the occupant of the seat100 in the event of a side impact to the vehicle or a rollover. Thedense foam material that forms the headrest 102 not only cradles theoccupant's head in the event of an accident, but also serves as acushion for sleeping.

Any number of different types of fasteners may be used to secure theheadrest to the headrest support. For example, the fasteners 360described above with two locking pieces 362, 364 may be used to securethe foam of the headrest 102 to the headrest support 130. Alternatively,loop and hook fastener material, such as VELCRO®, may be positioned onthe back side of the headrest 102 and used to secure the headrest 102 tothe headrest support 130. Low-density foam cushioning 124 may beattached to the headrest and headrest support to provide comfort paddingfor the back and head of the occupant of the child seat.

Seat Cover

As shown in FIGS. 10 and 11, a seat cover 108 covers the seat portion104, and a headrest cover 109 covers the headrest 102. Foam cushioning124 is placed on the foam shell, under the seat cover 108, to make theseat 100 more comfortable for the occupant. The seat cover 108 andheadrest cover 109 provide a comfortable feel to the seating surface ofthe child seat 100 and also provide an aesthetically pleasing anddesirable look to the child seat. The seat cover and headrest cover maybe constructed from any material that is conventionally used with seatsin the automotive vehicle industry, such as leather, vinyl, cloth, orthe like, or any materials used as cover materials in the juvenilefurniture industry, such as polyester, terry cloth, or the like.

In one embodiment, the seat cover 108 is designed for removal from thefoam shell 120 and base shell 118 without the need to remove any strapsfrom the harness of the child seat 100. This embodiment is generallyshown with reference to FIGS. 21 and 22. In this embodiment, the seatcover 108 and headrest cover 109 include a plurality of slits 380-384and a plurality of flaps 390-394. The slits and flaps allow the seatcover 108 and headrest cover 109 to be manipulated around the harnessstraps. For example, slit 384 allows the buckle 112 of the buckleharness system 211 (described below) to pass through the slit 384, andflap 394 may be opened to re-insert the buckle through the slit whenreattaching the cover to the seat. The backrest flaps 390 and 392 andslits 380 and 382 are other slits that may be manipulated when removingor attaching the cover. Seat cover fasteners, for example hook and looptype fasteners such as VELCRO®, are used to connect the slits and flapsand secure them in place on the seat while also providing a smoothermore uniform appearance to the seat. The periphery of the seat cover 108is designed to overlap the edges of the base shell 118. The periphery198 of the seat cover 108 is lined with an elastic material that helpsretain the seat cover 108 on the base shell 118.

Harness System

The harness system 110 is generally shown with reference to FIGS. 12-16.The harness system 110 includes a web 200 comprised of a plurality ofbelts/straps as well as several buckles. As shown in FIG. 12, theharness system 110 may be considered a two-part system, including ashoulder harness system 201 and a buckle harness system 211. Theconfiguration of the plurality of harness belts in relation to the frameare described for both the shoulder harness system and the buckleharness system with reference to FIG. 12. Thereafter, features of theharness system are described in relation to other portions of the childseat 100.

Shoulder Harness System

With reference to FIG. 12. The shoulder harness system 201 includes ashoulder belt 202 that includes a first end 204 fastened to one port ofa Y-connector 250 and a second end 206 fastened to another end of aY-connector 250. Starting with the first end 204, the shoulder beltmoves up from the Y-connector 250, over the cross member 129, and downunder the frame 122. After passing under the two short legs 132 of theL-shaped members 126, the shoulder belt 202 is passed back up to thecross member 129 on the other side of the frame 122. The shoulder belt202 then loops over the cross member 129 on the opposite side of thecross member from where it originally looped over, and follows back downto the Y-connector 250, where the shoulder belt 202 terminates and isagain fastened to the Y-connector (also see FIG. 4). The other beltfastened to the Y-connector 250 is a retraction belt 208. The retractionbelt moves down along the angled panel 156 of the base shell and, aftermaking turn, passes into the central channel of the base shell. A dottedline 118 is provided in FIG. 12 to represent this portion of the baseshell 118 in relation to the frame 122. After passing through thecentral channel of the base shell, the retraction belt 208 feeds intothe retractor (represented by dotted line 300). In particular, the endof the retraction belt is fastened to the feed bar 302 of the retractor.The feed bar may be turned in the direction of arrow 232 using knob 234(also see FIG. 1) to wind the retraction belt 208 in the retractor 300,thereby tightening the shoulder belt 202 and helping to secure anoccupant in the child seat 100. Conversely, the knob 234 and feed bar302 may be turned in the direction opposite arrow 232 to pay outadditional portions of the retraction belt 208 from the retractor,thereby providing additional slack for the shoulder belt when a largeroccupant is seated in the child seat 100.

Referring now to FIGS. 13-16, the shoulder harness system is shown withrespect to the frame 122, base shell 118, and headrest support 130. Asshown in FIG. 13, the shoulder belt 202 passes through both belt guides186 on the headrest support 130 as the shoulder belt 202 winds overcross bar 129 and under the bottom portion of the base shell 118.Although the shoulder belt 202 passes through the belt guides 186 on theheadrest support 130, the shoulder belt only slideably engages the beltguides and does not connect to the belt guides. This allows the headrestsupport 130 and attached headrest 102 to move up and down upon the frame122 and move to various positions, as discussed above, without the needfor removal, loosening or other adjustment of the harness 110, includingthe shoulder belt 202. Accordingly, the headrest 102 and associatedmechanism is independent of the harness 110. Furthermore, thisarrangement of the harness shoulder belt 202 passing through the beltguides 186 means that the headrest is not a load-bearing component ofthe child seat 100. The arrangement of the shoulder belt 202 upon theframe 122 means that most of the load is applied to the frame in theevent of a crash. The headrest may be adjusted to any position withoutloosening the harness.

Buckle Harness System

Referring again to FIG. 12, the harness belts 200 of the child seatfurther comprise belts in a buckle harness system 211. The buckleharness system 211 includes a crotch adjustment belt 214 and a crotchbelt 220. A first end 216 of the crotch adjustment belt 214 is insertedthrough the slit 198 in the headrest support 130 (represented by dottedlines 130 in FIG. 12) and is fastened to a buckle 260. The buckle 260secures the first end 216 to the headrest support 130, since the buckleis prevented from passing through the slit 198 to the headrest support130 (as shown in FIG. 16). The crotch adjustment belt 214 extends upfrom the buckle 260 and over the center portion of the cross bar 129.Then, the crotch adjustment belt 208 passes down to the cross bar 128 cand turns toward cross bar 128 b. After passing under cross bar 128 b,the crotch adjustment belt 208 is fastened to crotch adjustment bar 128a. An adjustable connector 240 is looped around the crotch adjustmentbelt 208 between the cross bars 128 a and 128 b such that the adjustableconnector 240 is free to slide upon the crotch adjustment belt 214. Oneend of a crotch belt 220 is securely fastened to the adjustableconnector 240. The opposite end of the crotch belt 220 is connected tothe buckle 112. As the headrest support 130 and associated first end 216of the crotch adjustment belt 214 move up, slack is provided in thecrotch adjustment belt 214. This slack allows the buckle 112 connectedto the crotch belt 220 to extend further away from cross bars 128 a and128 b. Conversely, when the headrest support 130 and associated firstend 216 of the crotch adjustment belt 214 move down, the crotchadjustment belt 214 is tightened and less of the belt is availablebetween cross bars 128 a and 128 b. With less belt available betweenthese cross bars, the fastener 240 and buckle 112 are pulled downwardtoward the cross bars 128 a and 128 b.

Referring now to FIGS. 14-15, the crotch adjustment belt 214 is shown intwo different positions. In FIG. 14, the crotch belt 214 is in anextended position. In this extended position, the headrest support 130and headrest 102 are moved fully up, providing slack in the crotchadjustment belt 214 that allows the adjustable connector 240 andattached crotch belt 220 to move to the extended position. In FIG. 15,the crotch adjustment belt is in a retracted position. In this retractedposition, the headrest support 130 and headrest 102 are moved fullydown, taking up slack in the crotch adjustment belt 214 to move thecrotch belt 220 to its retracted position. In this retracted position, aspacer 222 is shown encouraging the adjustable connector 240 morerearward. The spacer 222 is a plastic material that prevents theadjustable connector from contacting the portion of the belt 214 coveredby the spacer 222. Therefore, when little slack is available in the belt214, the adjustable connector and associated crotch belt are encouragedtoward the back of the seat. Accordingly, as the headrest 102 is movedup for taller (and larger) occupants, the buckle harness available tothe occupant lengthens and moves toward the front of the child seat. Asthe headrest is moved down, the buckle harness available to the occupantreduces in length and moves toward the rear of the seat. Accordingly, achild seat is provided that includes a buckle harness system 211 thatautomatically adjusts to the size of the occupant, based on the locationof the headrest 102. In an alternative embodiment shown in FIGS. 14A and15A, the front buckle 112 is not slidable along the crotch adjustmentbelt 214 as is the case in the embodiment shown in FIGS. 14 and 15.Rather, the front buckle 112 is attached to one end of the belt 214 asshown in FIGS. 14A and 15A. A tether belt 221 is added to limit upwardmovement of the front buckle 112. To this end, one end of the tetherbelt 221 is secured to the cross bar 128 b while the other end of thetether belt 221 is secured to the one end of the belt 214 as shown inFIGS. 14A and 15A.

Altogether, the disclosed harness system 110, including the shoulderharness system 201 and buckle harness system 211 provide means ofadjusting the shoulder and crotch strap heights to better fit with idealbelt positioning for children of various ages. Together, the shoulderharness system 201 and the buckle harness system 211 provide anintegrated child restraint system that can be adjusted to ideallyrestrain children of various weights and sizes. In one embodiment, theintegrated child restraint system is designed for restraining childrenfrom 22-65 lbs. The restraint system includes a means to adjust shoulderbelt heights while simultaneously positioning the crotch belt height andfore and aft position.

Central Belt Retractor

With reference to FIGS. 1 and 17-20, a central belt retractor 300 isprovided on the front portion of the base shell 118. As shown in FIG. 1,a decorative and protective covering 330 generally shields the centralretractor 300 when the seat is assembled. Removal of the protectivecovering 330 exposes the retractor 300.

As best shown in FIG. 18, the central retractor 300 includes a spool 306and latch 116 that cooperate in a ratchet fashion to wind the retractionbelt 208 on the spool. The spool 306 is retained within a retractorhousing 304 that is secured to cross bar 128 a. The spool 306 is mountedto an axle 302 that extends through the housing 304. As shown in FIGS.19A-19C, a wound power spring 320 connects the spool 306 to the axle 302and biases the spool toward clockwise movement, in the direction ofarrow 350, which will wind the retraction belt 208 on the spool. Thespool 306 includes two circular sidewalls 308 with ratchet teeth 310formed on the circular sidewalls. As shown in FIGS. 17 and 20, a handle324 is fixed to the end of the axle 302 to allow for manual rotation ofthe axle 302 and spool 306. In particular, manual rotation of the handle324 by a user will cause the retraction belt 208 to be wound upon thespool. As described previously, because the retraction belt 208 isconnected to the shoulder harness system 201, winding the retractionbelt 208 upon the spool will tighten the retraction belt 208 andshoulder belt 202 and generally tighten the shoulder harness on anoccupant of the seat.

Returning to FIG. 18, the latch 116 is provided for locking the spool306 in place. The latch 116 includes a front handle 318 and two pawls312 that extend rearwardly from the front handle 318. Each pawl 312includes a plurality of pawl teeth 310 designed to engage the spoolteeth 310 in a ratchet fashion. The latch 116 includes two pivot posts316 that connect the latch to the retractor housing 304. The latch 116also pivots within the housing 304 on the pivot posts 316. The fronthandle portion 318 of the latch 116 is biased downward by two springs326. Because the latch 116 is biased downward, the pawl teeth 314 areencouraged toward engagement with the spool teeth 310.

Rotation of the spool 306 in the clockwise direction, as noted by arrow350 in FIG. 18, results in the retraction belt 208 winding upon thespool 306. Because the spool 306 is spring biased, this rotation isgenerally automatic and acts to tighten the shoulder harness, asdescribed above. Because of the ratchet action between the spool teeth310 and the pawl teeth 314, the spool is normally blocked fromcounter-clockwise rotation, opposite the direction of arrow 350, whichwould allow the retraction belt 208 to be paid out. Furthermore, if theuser wishes to take up additional slack in the retraction belt 208 andattached shoulder belt 202, the handle 324 connected to the axis 302 maybe rotated in the direction of arrow 350, causing additional lengths ofthe retraction belt 208 to be wound upon the spool 306, and therebytightening the shoulder belt 202 upon the occupant of the seat.Additional lengths of belt wound upon the spool 306 are retained by thespool because of the ratchet action of the spool teeth 310 with the pawlteeth 314. When the user desires to pay out previously wound lengths ofthe retraction belt 208 in order to loosen the connected shoulder belt202, the latch handle 318 is moved upward. Upward movement of the latchhandle 318 releases the pawl teeth 314 from the spool teeth 310. Thisseparation allows the spool to rotate in a counter-clockwise direction,opposite the direction of arrow 350, and pay out additional lengths ofthe retraction belt 208 when the shoulder harness system 201 is pulledoutwardly. However, because the spool 308 is spring biased, slack in theretraction belt 208 and shoulder harness system 201 is removed once theuser stops pulling on the shoulder harness system. In this fashion, theshoulder harness system automatically tightens upon the occupant of thechild seat and secures the occupant in the seat.

Connection to Vehicle Seat

Returning to FIGS. 1, 3-5, 13, 17 and 20 a system is provided formounting the child seat 100 in a vehicle. In particular, vehicleconnection straps 270 are provided that are connected to vehicleconnection buckles 280. The connection straps are partially wound onretractable spools of retractors 290 (see FIG. 20) located under crossbar 128 a. The retractors 290 for the vehicle connection straps 270operate in a similar fashion to the retractor 300 for the retractionbelt 208 and connected shoulder belts 202 (as described above withreference to FIGS. 17-20). For example, similar to retractor 300, theretractors 290 for the vehicle connection straps 270 are spring biasedand automatically tighten the vehicle connection straps 270. Theretractors 290 may be released by pressing the buttons 284 located nextto the retraction latch 116 on the bottom front portion of the seat.Depression of one of the buttons 284 rotates a lever that releases apawl from engagement with teeth on the retractor 290. When the pawl isotherwise engaged with the teeth, the pawl locks the retractor 290 fromrotating in a direction that would pay out the vehicle connection strap270. When the pawl is released from the teeth by depression of thebutton 284, the retractor 290 is allowed to rotate and pay out thevehicle connection strap 270. In one embodiment, the buttons 284 areconnected by a connecting bar such that depression of either button 284will release both of the retractors 290. It should be appreciated thatthe retractors 290 and the vehicle connection buckles 280 may,respectively, be constructed and operate in the same or similar mannerto any of the retractors and vehicle connection buckles disclosed inPatent Publication No. U.S. 2004/0084939, the disclosure of which ishereby totally incorporated by reference in its entirety.

The vehicle connection straps 270 extend horizontally from the spools ofthe retractor 290 along the bottom portion of the base shell 118. At oneof the cross members 128 of the frame 122, the straps 270 make aperpendicular turn and extend vertically along the base shell.Thereafter, the connection straps pass through 45° slots 282 in the baseshell 118. The 45° slots 282 redirect the straps 270 in a generallyhorizontal direction such that the straps 270 extend sideways relativeto the upright child seat 100. The straps terminate in connectionbuckles 280 operable to connect to anchors in the vehicle seat.

In addition to the above method for connecting the vehicle seat to anautomobile, the vehicle seat may also be secured to an automobile bypassing the shoulder belt of the automobile through the triangularshaped openings 168 in the posterior portion of the base shell 118 andframe 122. After passing the shoulder belt through the openings 168, thebelts may be buckled to the shoulder belt anchors of the vehicle seatbelt and tightened, thus securing the child seat 100 to the vehicleseat.

Proper Harness Position Indicators

The child seat 100 is equipped with both a clip position indicator and ashoulder slot position indicator. The clip location indicator 396 isprovided on the clip itself. The clip position indicator 396 includes adesign, icon, wording, or other indicia to show the proper position ofthe clip relative to the child. For example, as shown in FIG. 23, theclip position indicator includes the words, “Adjust to armpit level.” Asalso shown in FIG. 23, shoulder pads 395 in the form of TPE pads areslideably positioned on the shoulder belts to provide shoulder paddingfor the child. As shown in FIG. 24, the shoulder pads 395 include atextured surface designed to provide friction against a child'sclothing, and thus prevent the TPE pads from slipping on the child whenthe child is secured in the seat by the harness.

In an alternative embodiment shown in FIG. 21A, the shoulder slotposition indicator is provided on the headrest cover 109. The shoulderslot position indicator includes a design, icon, wording, or otherindicia to show the proper position of the shoulder slot relative to thechild. For example, as shown in FIG. 21A, the shoulder slot positionindicator 398 includes a dotted line with words “Adjust this line aboveshoulders.” Together with the automated adjustment features of the childseat, the clip location indicator and the shoulder slot positionindicator help the consumer with proper positioning of the seat harnesson the child.

Carrying Strap/Tether Combination

With reference to FIG. 25, the child seat 100 includes a tether 500. Oneend of the tether 500 is secured to an upper posterior cross member onthe frame 122 (see FIG. 12). The other end of the tether 500 isconnected to a tether clip 502 that may be used to secure the tether 500to a tether anchor in an automobile. The tether clip includes a hookportion 504 and a buckle portion 506.

Conveniently, the tether 500 may also serve as a carrying strap. To thisend, the child seat 100 includes a tether clip connection slot 510 onthe posterior side of the base shell 118. The tether clip connectionslot 510 is dimensioned to receive the hook portion 504 of the tetherclip. Adjacent to the tether clip connection slot is a buckle groove 512dimensioned to receive the buckle portion 506 of the tether clip 502.

FIG. 25 shows the tether clip connection slot with the tether clip 502removed from the slot 510. FIG. 26 shows the tether clip connection slot510 with the hook portion 504 of the tether clip 502 hooked in the slot510 and the buckle portion 506 of the tether clip positioned in thegroove 512. As shown in FIG. 27, when the tether clip 502 is hooked inthe slot 512, a user may grab the tether 500 and place it over his orher shoulder as a means for conveniently carrying the child seat inback-pack fashion. The length of the tether/carrying strap 500 may beconveniently adjusted at the buckle portion 506, to accommodate the sizeof the user.

Instruction Manual Storage

With reference to FIGS. 28 and 29, the child seat 100 includes a pouch530 built into the headrest cover 109. The pouch 530 in the headrestcover 109 is generally rectangular in shape and is dimensioned toreceive the instruction manual for the child seat 100. The pouch 530 ispositioned on the top portion of the seat and the opening to the pouchis covered by a flap 532. The flap 532 includes one edge that is fixedto the headrest cover, and an opposing edge that connects to theheadrest cover using a fastener, such as a hook and loop fastener. Asshown in FIG. 29, pulling the edge of the flap back exposes the openingto the pouch 530 in the headrest cover.

When the headrest cover 109 is properly positioned on the headrest 102,the pouch 530 is situated in front of the foam headrest 102 and behindthe exterior surface of the headrest cover 109. Padding may be addedbetween the pouch 530 and the headrest cover 109. The pouch 530 providesa convenient location for storage of the instruction manual, allowing auser of the seat 100 to quickly and conveniently access the instructionmanual when needed. This convenient location for storage of theinstruction manual also helps the user avoid losing the instructionmanual.

Color Coded Parts and Instruction Manual

The instruction manual, seat labels, and various parts of the child seat100 are all color coded to help the user identify and properly operatedifferent parts on the seat. With reference to FIG. 32, a page 550 fromthe instruction manual is shown. This page 550 shows the child seat 100along with various component parts of the child seat. As noted by thispage 550 of the instruction manual, portions of the manual and seat 100color coded in yellow refer to the retractable harness 110 and relatedcomponents. Other portions of the instruction manual and seat 100 colorcoded in gray refer to the vehicle connection buckles 280 and relatedcomponents. Still other portions of the instruction manual and seat 100color coded in red refer to the vehicle seat belt and components forattaching the seat 100 to the vehicle seat belt. Of course any othercolor may be substituted for the colors described above such assubstituting the color black for the color gray.

As noted above, numerous text references in the instruction manual arehighlighted in yellow to indicate to the reader that the text being readis in reference to the retractable harness system 110 of the seat 100.Likewise, numerous parts on the seat 100 are yellow to help the usereasily identify and understand proper operation of the retractableharness system when reading about the retractable harness system in themanual. For example, with reference to FIG. 32, the knob 234 and theretraction latch 116 (color not shown) are both yellow in color. Thus,when the reader identifies yellow text in the instruction manual, he orshe may easily identify the component parts to which the instructionmanual refers for operation of the retractable harness system.

Additional Embodiments Anticipated

The child vehicle seat and restraint system disclosed herein is designedfor use in any moving vehicle, including, without limitation, cars,vans, trucks, airplanes, etc. Although the present invention has beendescribed with respect to certain preferred embodiments, it will beappreciated by those of skill in the art that other implementations andadaptations are possible. Moreover, there are advantages to individualadvancements described herein that may be obtained without incorporatingother aspects described above. Therefore, the spirit and scope of theinvention should not be limited to the description of the preferredembodiments contained herein.

1. A child vehicle seat, comprising: a seat assembly including (i) aseat portion having a first belt passage defined therein, and (ii) anupright portion having a second passage defined therein; a harnesssystem including (i) a shoulder belt portion extending through saidfirst belt passage, and (ii) a crotch belt portion extending throughsaid second belt passage; a retractor assembly configured to receivebelt portions of said harness system in a wound configuration, saidretractor assembly including a spring which urges belt portions of saidharness system into said retractor assembly; and an actuatorpositionable between (i) a first position in which said actuatorprevents payout of belt portions from said retractor assembly, and (ii)a second position in which said actuator allows payout of belt portionsfrom said retractor assembly, wherein said retractor assembly furtherincludes a manual adjustment mechanism, and wherein manual movement ofsaid manual adjustment mechanism causes further belt portions of saidharness system to be advanced into said retractor assembly.
 2. The childvehicle seat of claim 1, wherein: said retractor assembly includes aspool on which belt portions of said harness system are wound, and saidspring is configured to urge said spool in a rotating path of movement.3. The child vehicle seat of claim 2, wherein: said manual adjustmentmechanism includes a handle coupled to said spool, and rotation of saidhandle causes rotation of said spool.
 4. The child vehicle seat of claim3, wherein: ratchet teeth are formed on said spool, and said actuatorincludes a pawl configured to engage said ratchet teeth.
 5. The childvehicle seat of claim 1, wherein manual movement of said manualadjustment mechanism causes said shoulder belt portion to move throughsaid second belt passage defined in said upright portion.
 6. The childvehicle seat of claim 5, wherein urging of belt portions of said harnesssystem by said spring into said retractor assembly causes said shoulderbelt portion to move through said second belt passage defined in saidupright portion.
 7. The child vehicle seat of claim 6, wherein: saidharness system further includes a coupling belt and a connector, saidretractor is operable to advance portions of said coupling belt intosaid retractor, a second end of said coupling belt is secured to saidconnector, and said shoulder belt portion of said harness system issecured to said connector.
 8. The child vehicle seat of claim 1,wherein: an access opening is defined in a front portion of said seatassembly, and said actuator is positioned adjacent to said accessopening.
 9. A child vehicle seat, comprising: a seat assembly includingan upright portion having a passage defined therein; a harness systemincluding a shoulder belt portion extending through said passage; aretractor assembly configured to receive belt portions of said harnesssystem in a wound configuration, said retractor assembly including aspring which urges belt portions of said harness system into saidretractor assembly; and an actuator positionable between (i) a firstposition in which said actuator prevents payout of belt portions fromsaid retractor assembly, and (ii) a second position in which saidactuator allows payout of belt portions from said retractor assembly,wherein said retractor assembly further includes a manual adjustmentmechanism, and wherein manual movement of said manual adjustmentmechanism causes further belt portions of said harness system to beadvanced into said retractor assembly.
 10. The child vehicle seat ofclaim 9, wherein: said retractor assembly includes a spool on which beltportions of said harness system are wound, and said spring is configuredto urge said spool in a rotating path of movement.
 11. The child vehicleseat of claim 10, wherein: said manual adjustment mechanism includes ahandle coupled to said spool, and rotation of said handle causesrotation of said spool.
 12. The child vehicle seat of claim 11, wherein:ratchet teeth are formed on said spool, and said actuator includes apawl configured to engage said ratchet teeth.
 13. The child vehicle seatof claim 9, wherein manual movement of said manual adjustment mechanismcauses said shoulder belt portion to move through said passage definedin said upright portion.
 14. The child vehicle seat of claim 13, whereinurging of belt portions of said harness system by said spring into saidretractor assembly causes said shoulder belt portion to move throughsaid passage defined in said upright portion.
 15. The child vehicle seatof claim 14, wherein: said harness system further includes a couplingbelt and a connector, said retractor is operable to advance portions ofsaid coupling belt into said retractor, a second end of said couplingbelt is secured to said connector, and said shoulder belt portion ofsaid harness system is secured to said connector.
 16. The child vehicleseat of claim 9, wherein: an access opening is defined in a frontportion of said seat assembly, and said actuator is positioned adjacentto said access opening.
 17. A child vehicle seat, comprising: a seatassembly including an upright portion having a first passage and asecond passage defined therein; a harness system including (i) a firstshoulder belt portion extending through said first belt passage, and(ii) a second shoulder belt portion extending through said second beltpassage; a retractor assembly configured to receive belt portions ofsaid harness system in a wound configuration, said retractor assemblyincluding a spring which urges belt portions of said harness system intosaid retractor assembly; and an actuator positionable between (i) afirst position in which said actuator prevents payout of belt portionsfrom said retractor assembly, and (ii) a second position in which saidactuator allows payout of belt portions from said retractor assembly,wherein said retractor assembly further includes a manual adjustmentmechanism, and wherein manual movement of said manual adjustmentmechanism causes further belt portions of said harness system to beadvanced into said retractor assembly.
 18. The child vehicle seat ofclaim 17, wherein: said retractor assembly includes a spool on whichbelt portions of said harness system are wound, said spring isconfigured to urge said spool in a rotating path of movement, saidmanual adjustment mechanism includes a handle coupled to said spool, androtation of said handle causes rotation of said spool.
 19. The childvehicle seat of claim 1, wherein: manual movement of said manualadjustment mechanism causes both (i) said first shoulder belt portion tomove through said first belt passage, and (ii) said second shoulder beltportion to move through said second belt passage, and urging of beltportions of said harness system by said spring into said retractorassembly causes both (i) said first shoulder belt portion to movethrough said first belt passage, and (ii) said second shoulder beltportion to move through said second belt passage.
 20. The child vehicleseat of claim 19, wherein: said harness system further includes acoupling belt and a connector, said retractor is operable to advanceportions of said coupling belt into said retractor, a second end of saidcoupling belt is secured to said connector, and said shoulder beltportion of said harness system is secured to said connector.